ENGINE COOLING SYSTEM

B ENGINE

CO
SECTION
ENGINE COOLING SYSTEM C

E
CONTENTS
PRECAUTIONS .......................................................... 2 Removal and Installation (Except for the Middle F
Precautions for Supplemental Restraint System East) ....................................................................... 21
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- REMOVAL ........................................................... 21
SIONER” .................................................................. 2 INSPECTION AFTER REMOVAL ....................... 22 G
Precautions for Liquid Gasket .................................. 2 INSTALLATION ................................................... 22
REMOVAL OF LIQUID GASKET SEALING .......... 2 INSPECTION AFTER INSTALLATION ................ 23
LIQUID GASKET APPLICATION PROCEDURE..... 2 Disassembly and Assembly .................................... 23
H
PREPARATION ........................................................... 4 DISASSEMBLY ................................................... 23
Special Service Tools ............................................... 4 ASSEMBLY ......................................................... 24
OVERHEATING CAUSE ANALYSIS .......................... 5 Removal and Installation (For the Middle East) ...... 24
Troubleshooting Chart .............................................. 5 REMOVAL ........................................................... 25 I
COOLING SYSTEM .................................................... 7 INSTALLATION ................................................... 25
Cooling Circuit .......................................................... 7 Disassembly and Assembly .................................... 25
EXCEPT FOR THE MIDDLE EAST ...................... 7 DISASSEMBLY ................................................... 25 J
FOR THE MIDDLE EAST ..................................... 8 ASSEMBLY ......................................................... 25
ENGINE COOLANT .................................................. 10 WATER PUMP .......................................................... 26
Inspection ............................................................... 10 Removal and Installation (Except for the Middle
K
LEVEL CHECK ................................................... 10 East) ....................................................................... 26
LEAK CHECK ..................................................... 10 REMOVAL ........................................................... 26
Changing Engine Coolant ...................................... 10 INSPECTION AFTER REMOVAL ....................... 27
DRAINING ENGINE COOLANT ......................... 10 INSTALLATION ................................................... 27 L
REFILLING ENGINE COOLANT .........................11 INSPECTION AFTER INSTALLATION ................ 27
FLUSHING COOLING SYSTEM ......................... 12 Removal and Installation (For the Middle East) ...... 27
RADIATOR ................................................................ 13 REMOVAL ........................................................... 28 M
Removal and Installation ........................................ 13 INSPECTION AFTER REMOVAL ....................... 28
EXCEPT FOR THE MIDDLE EAST .................... 13 INSTALLATION ................................................... 28
FOR THE MIDDLE EAST ................................... 14 THERMOSTAT AND WATER CONTROL VALVE ... 29
REMOVAL ........................................................... 14 Removal and Installation ........................................ 29
INSTALLATION ................................................... 15 REMOVAL ........................................................... 29
CHECKING RADIATOR CAP (RESERVOIR INSPECTION AFTER REMOVAL ....................... 30
TANK CAP FOR THE MIDDLE EAST ) ............... 15 INSTALLATION ................................................... 30
CHECKING RADIATOR ...................................... 15 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 31
RADIATOR (ALUMINUM TYPE) .............................. 17 Standard and Limit .................................................. 31
Disassembly and Assembly ................................... 17 CAPACITY ........................................................... 31
PREPARATION ................................................... 17 THERMOSTAT .................................................... 31
DISASSEMBLY ................................................... 17 WATER CONTROL VALVE ................................. 31
ASSEMBLY ......................................................... 18 RADIATOR .......................................................... 31
INSPECTION ...................................................... 20 Tightening Torque ................................................... 31
COOLING FAN ......................................................... 21

CO-1
 PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EBS005GS

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connec-
tors.
Precautions for Liquid Gasket EBS005GT

REMOVAL OF LIQUID GASKET SEALING

● After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
● In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the area where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.
PBIC0275E

LIQUID GASKET APPLICATION PROCEDURE

1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
● Remove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
PBIC0003E

4. Apply the gasket without breaks to the specified location with the
specified dimensions.
● If there is a groove for the liquid gasket application, apply the
gasket to the groove.

EMA0622D

CO-2
 PRECAUTIONS

● As for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure A
to read the text of this manual.
● Within five minutes of gasket application, install the mating com-
ponent. CO
● If the liquid gasket protrudes, wipe it off immediately.
● Do not retighten after the installation.
● After 30 minutes or more have passed from the installation, fill C
the engine oil and coolant.
CAUTION: SEM164F
If there are specific instructions in this manual, observe them. D

CO-3
 PREPARATION

PREPARATION PFP:00002

Special Service Tools EBS005GU

Tool number
Description
Tool name

WS39930000 Pressing the tube of liquid gasket

Tube pressure

S-NT052

EG17650301 Adapting radiator cap tester to radiator cap

Radiator cap tester adapter and radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)

S-NT564

KV99103510 Installing radiator upper and lower tanks

Radiator plate pliers A

S-NT224

KV99103520 Removing radiator upper and lower tanks

Radiator plate pliers B

S-NT225

CO-4
 OVERHEATING CAUSE ANALYSIS

OVERHEATING CAUSE ANALYSIS PFP:00012

A
Troubleshooting Chart EBS005GW

Symptom Check items

Water pump malfunction Worn or loose drive belt CO
Thermostat stuck closed —
Dust contamination or
C
Poor heat transfer Damaged fins paper clogging —
Mechanical damage
Clogged radiator cooling Excess foreign material D
tube (rust, dirt, sand, etc.)
Cooling fan does not oper-
ate
E
Reduced air flow High resistance to fan rota- — —
tion
Damaged fan blades
F
Damaged radiator shroud — — —
Improper coolant mixture
Cooling sys- — — —
ratio G
tem parts
malfunction Poor coolant quality — — —
Loose clamp
Cooling hose H
Cracked hose
Water pump Poor sealing
Loose
Radiator cap I
Poor sealing
Coolant leaks
O-ring for damage, deterio-
Insufficient coolant ration or improper fitting J
Radiator
Cracked radiator tank
Cracked radiator core
Reservoir tank Cracked reservoir tank K
Cylinder head deterioration
Exhaust gas leaks into
Overflowing reservoir tank Cylinder head gasket dete-
cooling system L
rioration

CO-5
 OVERHEATING CAUSE ANALYSIS

Symptom Check items

High engine rpm under no
load
Driving in low gear for
Abusive driving
extended time
Driving at extremely high
speed
— Overload on engine
Powertrain system mal-
function
Installed improper size
Except cool- —
wheels and tires
ing system
parts mal- Dragging brakes
function
Improper ignition timing
Blocked bumper —
Installed car brassiere
Blocked radiator grille Mud contamination or
Blocked or restricted air paper clogging —
flow
Blocked radiator —
Blocked condenser
—
Installed large fog lamp

CO-6
 COOLING SYSTEM

COOLING SYSTEM PFP:21020

A
Cooling Circuit EBS005GX

EXCEPT FOR THE MIDDLE EAST

CO

PBIC0159E
J

CO-7
 COOLING SYSTEM

PBIC0160E

FOR THE MIDDLE EAST

PBIC0646E

CO-8
COOLING SYSTEM

CO

PBIC1010E
I

CO-9
 ENGINE COOLANT

ENGINE COOLANT PFP:KQ100

Inspection EBS005GY

LEVEL CHECK
● Check if the reservoir tank coolant level within MIN to MAX
When engine cool.
● Adjust coolant if too much or too little.

SMA412B

LEAK CHECK
● To check for leakage, apply pressure to the cooling system with
a tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)
WARNING:
Never remove the radiator cap(including reservoir tank capfor
the Middle East) when the engine is hot. Serious burns could
occur from high pressure coolant escaping from the radiator.
CAUTION: SLC756AA
Higher pressure than specified may cause radiator damage.
Changing Engine Coolant EBS005GZ

WARNING:
● To avoid being scalded, never change the coolant when the engine is hot.
● Wrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn
to release built-up pressure. Then turn the cap all the way.
DRAINING ENGINE COOLANT
1. Remove under cover.
2. Open radiator drain plug at the bottom of radiator, and remove filler cap.
● Be careful not to allow coolant to contact drive belts.
When draining all the coolant in the system,also perform the following steps.
3. Remove air relief plug on heater hose.

PBIC0235E

CO-10
 ENGINE COOLANT

4. Drain coolant from both sides of cylinder block when draining all
the coolant in the system. A

CO

PBIC0145E

G
PBIC0146E

5. Check drained coolant for contaminants such as rust, corrosion or discoloration.

H
If contaminated, flush engine cooling system. Refer to CO-12, "FLUSHING COOLING SYSTEM" .
6. Remove reservoir tank, drain coolant, then clean reservoir tank.
REFILLING ENGINE COOLANT I
1. Install reservoir tank if removed, and radiator drain plug.
2. Install cylinder block drain plugs if removed.
Apply sealant to the thread of cylinder block drain plugs. J
● Use Genuine Thread Sealant Part No. 999MP-AM002P or equivalent.

: 14.7 - 24.5 N·m (1.5 - 2.5 kg-m , 11 - 18 ft-lb) K

3. Fill radiator and reservoir tank to specified level.
● Use genuine Nissan anti-freeze coolant or equivalent mixed
with water (distilled or demineralized). L
Refer to MA-8, "RECOMMENDED FLUIDS AND LUBRI-
CANTS".
Engine coolant capacity (With reservoir tank): M
Except for the Middle East
Approximately 9.8 (8-5/8 Imp qt)
For the Middle East
SMA182B
Approximately 10.5 (9-1/4 Imp qt)

CO-11
 ENGINE COOLANT

Reservoir tank capacity:

0.8 (7/8 US qt, 3/4 lmp qt)
● Pour coolant through coolant filler neck slowly of less than
2 (1-3/4 Imp qt) a minute to allow air in system to escape.
● When coolant overflows air relief hole on heater hose, install air
relief plug.
4. Warm up engine to normal operating temperature with radiator
cap installed.
5. Run engine at 3,000 rpm for 10 seconds and return to idle SMA412B
speed.
● Repeat two or three times.
Watch coolant temperature gauge so as not to overheat the engine.
6. Stop engine and cool down to less than approximately 50°C (122°F).
● Cool down using a fan to reduce the time.
● If necessary, refill radiator up to filler neck with coolant.
7. Refill reservoir tank to MAX level line with coolant.
8. Repeat steps 4 through 6 two or more times with radiator cap installed until coolant level no longer drops.
9. Check cooling system for leaks with engine running.
10. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with
heater temperature controller set at several position between COOL and WARM.
● Sound may be noticeable at heater unit.
11. Repeat step 9 three times.
12. If sound is heard, bleed air from cooling system by repeating steps 4 through 6 until coolant level no
longer drops.
● Clean excess coolant from engine.
FLUSHING COOLING SYSTEM
1. Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and
reservoir tank with water and reinstall radiator cap.
2. Run engine and warm it up to normal operating temperature.
3. Rev engine two or three times under no-load.
4. Stop engine and wait until it cools down.
5. Drain water.
6. Repeat steps 1 through 5 until clear water begins to drain from radiator.

CO-12
 RADIATOR

RADIATOR PFP:21400
A
Removal and Installation EBS00DLH

EXCEPT FOR THE MIDDLE EAST

CO

PBIC0928E
J
1. Radiator 2. Bracket 3. Mounting rubber
4. Clip 5. Mounting rubber 6. O-ring
7. Radiator coolant temperature sensor 8. Radiator hose (lower) 9. Reservoir tank hose K
10. Reservoir tank 11. Bracket 12. Cap
13. A/T oil cooler hose 14. Drain plug 15. Cooling fan shroud
16. O-ring 17. Radiator hose (upper) 18. Bracket L

CO-13
 RADIATOR

FOR THE MIDDLE EAST

PBIC0931E

1. Radiator hose (upper) 2. Bracket 3. Mounting rubber

4. Clip 5. Radiator 6. O-ring
7. Drain plug 8. Mounting rubber 9. A/T oil cooler hose
10. Radiator hose (lower) 11. Cooling fan shroud 12. Reservoir tank cap
13. Reservoir tank hose 14. Bracket 15. Reservoir tank

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
coolant escaping from the radiator.
REMOVAL
1. Drain coolant.
CAUTION:
Perform when the engine is cold.
2. Remove cooling fan shroud. Refer to CO-21, "Removal and Installation (Except for the Middle East)"
(EXCEPT FOR THE MIDDLE EAST), CO-24, "Removal and Installation (For the Middle East)" (FOR THE
MIDDLE EAST).
3. Remove A/T oil cooler hoses.
● Install blind plug to void leakage of A/T fluid.

4. Remove bolts of both right/left end of radiator core (2 bolts for each).

CO-14
 RADIATOR

5. Lift the air condenser up approximately 2 cm (0.79 in).

Remove the clips from the right and left flange parts of the con- A
denser.
CAUTION:
To avoid putting a load on the air conditioner piping, be careful CO
not to lift too much.
6. Lift up and remove the radiator.
CAUTION: C
● Do not damage or scratch radiator core when removing.
● After removing the radiator, fix the air condenser on the PBIC0148E
vehicle side with a rope or similar means. This is to prevent D
a load being applied to the air conditioner piping.
INSTALLATION
● Install in the reverse order of removal. E
● Align ID marks to install clips of both right/left end of radiator core. Refer to Radiator component illustra-
tion on top page.
CHECKING RADIATOR CAP (RESERVOIR TANK CAP FOR THE MIDDLE EAST ) F
1. Pull the negative pressure valve to open it and check that it
close completely when released.
● Check that there is no dirt or damage on the valve seat of the G
radiator cap negative-pressure valve.
● Check that there are no abnormalities in the opening and closing
conditions of the negative-pressure valve. H

I
SMA967B

J
2. Check radiator cap relief pressure.
Standard:
78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2 , 11 - 14 K
psi) except for the Middle East
98 -118 kpa (0.98 - 1.18 bar, 1.0 - 1.2 kg/cm2 , 14 - 17
psi) for the Middle East L
Limit:
59 kPa (0.59 bar, 0.6 kg/cm2 , 9 psi) M
SLC755AC
● When connecting the radiator cap to the tester, apply water or
LLC to the cap seal part.
● Replace the radiator cap if there is an abnormality in the negative-pressure valve, or if the open-valve
pressure is outside of the standard values.
CHECKING RADIATOR
Check radiator for mud or clogging. If necessary, clean radiator as follow
● Be careful not to bend or damage the radiator fins.
● When radiator is cleaned without removal, remove all surrounding parts such as cooling fan shroud and
horns. Then tape the harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the radiator core vertically download.
2. Apply water again to all radiator core surfaces once per minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically download.
● Use compressed air lower than 490 kPa (5 kg/cm2 , 71 psi) and keep distance more than 30 cm (11.8 in).

CO-15
 RADIATOR

5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.

CO-16
 RADIATOR (ALUMINUM TYPE)

RADIATOR (ALUMINUM TYPE) PFP:21460

A
Disassembly and Assembly EBS005H1

CO

SLC882AB
G

PREPARATION
1. Attach the spacer to the tip of the radiator plate pliers A. H
Spacer specification: 1.5 mm (0.059 in) thick x 18 mm (0.71 in)
wide x 8.5 mm (0.335 in) long.
2. Make sure that when radiator plate pliers A are closed dimen-
I
sion H′′ is approx. 7.6 mm (0.299 in).
3. Adjust dimension H′′ with the spacer, if necessary.
J

SLC655C K
DISASSEMBLY
1. Remove tank with Tool.
L

SLC903

CO-17
 RADIATOR (ALUMINUM TYPE)

● Grip the crimped edge and bend it upwards so that Tool slips off.
Do not bend excessively.

SLC893

● In areas where Tool cannot be used, use a screwdriver to bend

the edge up.
Be careful not to damage tank.

SLC930

2. Make sure the edge stands straight up.

3. Remove oil cooler from tank. (A/T model only)

SLC931

ASSEMBLY
1. Install oil cooler. (A/T model only)
Pay attention to direction of conical washer.

SLC894

CO-18
 RADIATOR (ALUMINUM TYPE)

2. Clean contact portion of tank.

A

CO

SLC932

D
3. Install sealing rubber.
Push it in with fingers.
Be careful not to twist sealing rubber. E

G
SLC917A

4. Caulk tank in specified sequence with Tool. H

K
SLC904

SLC896

● Use pliers in the locations where Tool cannot be used.

SLC897

CO-19
 RADIATOR (ALUMINUM TYPE)

5. Make sure that the rim is completely crimped down.

Standard height “H” : 8.0 - 8.4 mm (0.315 - 0.331 in)
6. Confirm that there is no leakage.
Refer to Inspection.

SLC554A

INSPECTION
1. Apply pressure with Tool.
Specified pressure value:
157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi)
WARNING:
To prevent the risk of the hose coming undone while under
pressure, securely fasten it down with a hose clamp.
Attach a hose to the oil cooler as well. (A/T model only)

SLC933

2. Check for leakage.

SLC934

CO-20
 COOLING FAN

COOLING FAN PFP:21140

A
Removal and Installation (Except for the Middle East) EBS005H2

CO

PBIC1011E

Cooling fan pump (with water pump)

1. 2. O-ring 3. Fluid hose
(Do not disassemble.)
Cooling fan motor
4. Fluid hose 5. 6. Cooling fan shroud
(Do not disassemble.)
7. Fan 8. Cooling fan fluid cooler 9. Clip
10. Fluid hose 11. Fluid hose 12. Reservoir tank

REMOVAL
1. Remove air duct and air cleaner case. Refer to EM-16, "Removal and Installation" .
2. Remove under cover.
3. Drain coolant. Refer to CO-10, "Changing Engine Coolant" .

CO-21
 COOLING FAN

CAUTION:
● Perform when the engine is cold.

● Never remove the radiator cap when the engine is hot. Serious burns could occur from high
pressure fluid escaping from the radiator.
4. Remove battery.
5. Remove the vacuum tank from the front of the engine.
6. Disconnect the radiator hoses (upper/lower).
7. Remove the following parts from the fan shroud: coolant temperature sensor harness, coolant reservoir
tank hose, A/T oil cooler hose, mounting bolts for the cooling fan fluid hose bracket.
8. Drain the cooling fan fluid.
● Because there is no drain plug on the reservoir tank or piping, drain the fluid from the reservoir tank oil
inlet and pipe division points.
● Prepare a container with a volume of approximately 1 (1-3/4 Imp pt) to drain the fluid into.
9. Remove the cooling fan fluid reservoir tank.
10. Disconnect the hoses between the cooling fan motor and cooling fan pump (joined with the water pump),
and the hose between the cooling fan motor and the oil cooler.
● Fluid will leak, so have shop cloths ready.

11. Remove the cooling fan shroud mounting bolts.

12. Remove the radiator mounting bracket. With the radiator moved toward the vehicle front, lift up and
remove the cooling fan.
CAUTION:
● Be careful not to scratch or damage the radiator core.
● When removing the cooling fan pump, remove it together with the water pump. (They can not be
separated.) Refer to CO-26, "Removal and Installation (Except for the Middle East)" .
● When removing the cooling fan fluid cooler, be careful not to scratch or damage the air condi-
tioner condenser core.
INSPECTION AFTER REMOVAL
● Turning oil cooling fan motor shaft by hands check if it rotates smoothly without looseness.
● Check visually for fluid leakage from cooling fan motor.
● For oil pump inspection, refer to CO-26, "WATER PUMP" .
INSTALLATION
Install in the reverse order of removal referring the following.
● For bleeding the air from the cooling system. Refer to CO-11, "REFILLING ENGINE COOLANT" .
Attaching the fluid pipe fixing clip
● If the fluid pipe fixing clip has been removed from the installation holes, it must be replaced with a new
clip.
Adding cooling fan fluid and bleeding air
● The procedure below is for adding cooling fan fluid and bleeding air from the piping.
CAUTION:
Do not reuse the used fluid which was drained out.
Use genuine DEXRONTM lll or equivalent. Refer to MA-8, "RECOMMENDED FLUIDS AND LUBRI-
CANTS" .
NOTE:
The total fluid volume is 777 ml (27.4 Imp floz) (with the cold maximum on the level gauge when the engine is
cold).
1. Add fluid to the reservoir tank until the fluid reaches the upper limit of the “hot” level on the level gauge.
For the fluid level, refer to CO-23, "INSPECTION AFTER INSTALLATION" .
2. Start the engine.
3. Run the engine at idle speed for a few minutes. Then check the fluid level. If the level has decreased, add
fluid.
CAUTION:
● Be careful not to touch the fan while it is rotating.
CO-22
 COOLING FAN

● Be sure to add fluid as necessary. If the fluid runs out in the reservoir tank, air will be taken in.
NOTE: A
● With the engine operating, the reservoir tank cap can be removed to check the fluid level.
● Immediately after starting, certain noise will come from the fluid pump. This is caused by air taken in to the
piping and will gradually disappear. CO
4. Continue with step 3 until the level of the fluid stops decreasing.
5. Stop the engine and remove the harness connector for the cool-
ing fan control solenoid. C
NOTE:
When the solenoid harness is disconnected, the fan will operate at
full speed. D
6. Start the engine. Repeat step 3 until the fluid level stops
decreasing and air bubbles stop coming out.
7. Stop the engine. Connect the harness connector for the cooling E
fan control solenoid.
PBIC0150E

F
INSPECTION AFTER INSTALLATION
● Check that there is no fluid leakage from any hose connection or
any other part.
G
● Check the fluid level with the level gauge on the reservoir tank
cap. If there is too much or too little, adjust the amount of fluid.
● Check that under the fluid temperature conditions below, the H
fluid level is within the “cold” or “hot” range on the level gauge.
Cold : Fluid temperature 0 - 30 °C (32 - 86 °F)
Hot : Fluid temperature 50 - 80 °C (122 - 176 °F) I
NOTE: PBIC0151E
● There is no specified timing for replacing the fluid.
J
● Refer to EC-343, "DTC P1480 COOLING FAN SPEED CONTROL SOLENOID VALVE (CIRCUIT)" for
control of cooling fan.
Disassembly and Assembly EBS00II6
K
DISASSEMBLY
1. Remove fan.
CAUTION: L
● Reverse screws are used for the fan attachment nuts.
When removing or attaching, turn the nut the opposite
way as for a normal screw.
M
● Do not remove the balancer clip from the fan.

● For the case if the balancer clip is removed, make an

alignment mark for the installation position on the fan
side.
PBIC0152E

CO-23
 COOLING FAN

2. Remove cooling fan motor from cooling fan shroud.

PBIC0153E

ASSEMBLY
● Assemble in the reverse order of disassembly.
Removal and Installation (For the Middle East) EBS00HW7

PBIC0932E

1. Cooling fan motors 2. Cooling fan shroud 3. Fans

CO-24
 COOLING FAN

REMOVAL
1. Remove air duct and air cleaner case. Refer to EM-16, "Removal and Installation" . A
2. Remove under cover.
3. Drain coolant. Refer to CO-10, "Changing Engine Coolant" .
CO
CAUTION:
● Perform when the engine is cold.

● Never remove the radiator cap when the engine is hot. Serious burns could occur from high
pressure fluid escaping from the radiator. C
4. Remove battery.
5. Remove the vacuum tank from the front of the engine.
D
6. Disconnect the radiator hoses (upper/lower).
7. Remove the A/T oil cooler hose from the fan shroud.
8. Disconnect harness connector from fan motor. E
9. Remove the cooling fan shroud mounting bolts.
10. Remove the radiator mounting bracket. With the radiator moved toward the vehicle front, lift up and
remove the cooling fan. F
CAUTION:
● Be careful not to scratch or damage the radiator core.
INSTALLATION G
Install in the reverse order of removal.
NOTE:
● Cooling fan is controlled by ECM. For details, refer to EC-313, "DTC P1217 ENGINE OVER TEMPERA- H
TURE (OVERHEAT)(FOR MIDDLE EAST)" .
Disassembly and Assembly EBS00IHY
I
DISASSEMBLY
1. Remove fans.
2. Remove cooling fan motors from cooling fan shroud.
J
ASSEMBLY
● Assemble in the reverse order of disassembly.
K

CO-25
 WATER PUMP

WATER PUMP PFP:21020

Removal and Installation (Except for the Middle East) EBS005H4

PBIC0989E

Water pump
1. 2. O-ring 3. Fluid hose (feed side)
(Do not disassemble.)
Cooling fan pump
4. Fluid hose (return side) 5. Water pump pulley 6.
(Do not disassemble.)
Cooling fan speed control solenoid
7. 8. Gasket
valve (Do not disassemble.)

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
fluid escaping from the radiator.
REMOVAL
1. Drain coolant so that no coolant comes out from water pump fitting hole.
CAUTION:
Perform when the engine is cold.
2. Remove below the parts.
● Under cover

● Air duct and engine room cover

For removing engine room cover, refer to EM-11, "Removal and Installation" .
● Alternator, water pump and A/C compressor belt
For removing drive belt, refer to EM-13, "Removal and Installation" .
CAUTION:
Leave the fixed tensioner pulley in its fixed position when removing the drive belt.
3. Remove the harness connector for the cooling fan speed control solenoid valve (joined with the water
pump).
4. Remove the water pump pulley.
5. Disconnect the cooling fan fluid hose.
● Because there is no drain plug, drain the fluid from the hose separation point.

● Prepare a receptacle with a volume of approximately 1 (1-3/4 Imp pt).

6. Remove the water pump.
● Coolant will leak from the cylinder block, so have a receptacle ready below.

CAUTION:
● Handle the water pump vane so that it does not contact any other parts.

CO-26
 WATER PUMP

● Do not disassemble the water pump (including the cooling fan pump and cooling fan speed con-
trol solenoid). A
INSPECTION AFTER REMOVAL
● Visually check that there is no significant dirt or rusting on the
water pump body and vane. CO
● Check that there is no looseness in the vane shaft, and that it
turns smoothly when rotated by hand.
● Visually check that there is no fluid leakage from the cooling fan C
pump part and the cooling fan speed control solenoid part.
● If there are any unusualness, replace the water pump assembly.
D

PBIC0155E
E
INSTALLATION
● Install in the reverse order of removal.
● Apply type DexronTM lll or equivalent to the O-ring of the cooling fan fluid hose (on the feed side). Then F
insert the O-ring to the water pump so that it does not come out of the attachment groove.
● For bleeding the air from the cooling system, refer to CO-11, "REFILLING ENGINE COOLANT" .
● For bleeding the air from the cooling fan fluid, refer to CO-22, "INSTALLATION" . G

INSPECTION AFTER INSTALLATION

● After installing water pump, check for leaks using radiator cap tester. H
Removal and Installation (For the Middle East) EBS00DLK

PBIC0988E

1. Water pump 2. Water pump pulley 3. Gasket

WARNING:
Never remove the radiator cap or reservoir tank cap when the engine is hot. Serious burns could be
caused by high pressure fluid escaping from the radiator or reservoir tank.

CO-27
 WATER PUMP

REMOVAL
1. Drain engine coolant.
CAUTION:
Perform when the engine is cold.
2. Remove below the parts.
● Under cover

● Air duct and engine room cover

For removing engine room cover, refer to EM-11, "Removal and Installation" .
● Alternator, water pump and A/C compressor belt
For removing drive belt, refer to EM-13, "Removal and Installation" .
CAUTION:
Leave the fixed tensioner pulley in its fixed position when removing the drive belt.
3. Remove the water pump pulley.
4. Remove water pump.
● Remove water pump with lightly tapping it using wooden piece.
CAUTION:
Do not disassemble water pump.
INSPECTION AFTER REMOVAL
● Visually check that there is no significant dirt or rusting on the water pump body and vane.
● Check that there is no looseness in the vane shaft, and that it turns smoothly when rotated by hand.
INSTALLATION
Install in the reverse order of removal.

CO-28
 THERMOSTAT AND WATER CONTROL VALVE

THERMOSTAT AND WATER CONTROL VALVE PFP:21200

A
Removal and Installation EBS005H5

CO

PBIC0156E
K
1. Water connector 2. O-ring 3. Rubber ring
4. Heater hose 5. Water control valve 6. Rear water outlet
7. Gasket 8. O-ring 9. Water outlet pipe L
10. Thermostat housing 11. Radiator cap 12. Radiator upper hose
13. Thermostat 14. Rubber ring 15. Water inlet
16. Water suction hose 17. Water suction pipe 18. Radiator lower hose M
19. Gasket 20. O-ring 21. Heater pipe
22. Heater hose

WARNING:
Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure
fluid escaping from the radiator.
REMOVAL
1. Drain engine coolant.
CAUTION:
Perform when the engine is cold.
2. Remove air duct and engine room cover. For removing engine room cover, refer to EM-11, "Removal and
Installation" .
3. Remove water suction hose from water inlet side.
4. Remove water inlet and thermostat.
5. Remove intake manifold upper, intake manifold lower and water control valve.

CO-29
 THERMOSTAT AND WATER CONTROL VALVE

6. Remove fuel injector harness, thermostat housing, water outlet pipe, rear water outlet and heater pipe
(between left and right banks).
INSPECTION AFTER REMOVAL
● Place a thread so that it is caught in the valves of the thermostat
and water control valve. Immerse fully in a container filled with
water. Heat while stirring. (The example in the figure shows the
thermostat.)
● The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
● Continue heating. Check the full-open lift amount.
NOTE:
The full-open lift amount standard temperature for the water
control valve is the reference value.
SLC252B
● After checking the full-open lift amount, lower the water temper-
ature and check the valve closing temperature.
Standard values
Thermostat Water control valve
Valve opening temperature 80 - 84°C (176 - 183° F) 93.5 - 96.5°C (200 - 206°F)
More than 10 mm/ 95°C More than 8 mm/ 108°C
Full-open lift amount
( 0.39 in/ 203 °F) (0.315 in/ 226 ° F)
Valve closing temperature 77°C (171°F) or higher 90°C (194° F) or higher

INSTALLATION
● Install in the reverse order of removal.
Installation of thermostat and water control valve
● Install the thermostat and water control valve with the whole cir-
cumference of each flange part fit securely inside the rubber
ring. (The example in the figure shown the thermostat.)

PBIC0157E

● Install the thermostat with the jiggle-valve facing upwards. (The

position deviation may be within the range of ±10°)
● Install the water control valve with the up-mark facing up and the
frame center part facing upwards. (The position deviation may
be within the range of ±10°)

PBIC0158E

Installation of water outlet pipe and heater pipe

● First apply a neutral detergent to the O-rings, then quickly insert the insertion parts of the water outlet pipe
and heater pipe into the installation holes.

CO-30
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
Standard and Limit EBS005H6

CAPACITY
Approximately 9.8 (8-5/8 Imp qt) except for the Middle CO
Coolant capacity [With reservoir tank (MAX level)] East
Approximately 10.5 (9-1/4 lmp qt) for the Middle East
Cooling fan fluid capacity 777 m (27.4 Imp floz) C
THERMOSTAT
Valve opening temperature 80 - 84°C (176 - 183°F)
D
Valve lift More than 10 mm/95°C (0.39 in/203°F)

WATER CONTROL VALVE

E
Valve opening temperature 93.5 - 96.5°C (200 - 206°F)
Valve lift More than 8 mm/108°C (0.315 in/226°F)

RADIATOR F
Unit: kPa (bar, kg/cm2 , psi)
78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11- 14) except for
the Middle East G
Radiator cap relief pressure (Reser- Standard
98 - 118 (0.98 - 1.18, 1.0 - 1.2, 14 - 17) for the
voir tank cap for the Middle East) Middle East
Limit 59 (0.59, 0.6, 9) H
Leakage test pressure 157 (1.57, 1.6, 23)

Tightening Torque EBS005H7

I
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)*
Cylinder block drain plug 14.7 - 24.5 (1.5 - 2.5, 11 - 18)
J
Radiator mounting bracket 3.8 - 4.5 (0.39 - 0.46, 34 - 39)*
Radiator drain plug 0.78 - 1.6 (0.08 - 0.16, 7 - 13)*
Radiator coolant temperature sensor 4.9 - 9.8 (0.5 - 1.0, 44 - 86)*
Cooling fan shroud 3.8 - 4.5 (0.39 - 0.46, 34 - 39)* K
Fan (Except for the Middle East) 7.8 - 11.8 (0.80 - 1.2, 70 - 104)*
Fan (For the Middle East) 2.9 - 3.9 (0.30 - 0.40, 26 - 34)*
Fan motor 3.9 - 4.9 (0.40 - 0.49, 35 - 43)*
Cooling fan fluid cooler 3.0 - 3.9 (0.31 - 0.40, 27 - 34)* L
Water pump pulley 7.2 - 9.2 (0.73 - 0.94, 64 - 81)*
Water pump 24.5 - 31.4 (2.5 - 3.2, 18 - 23)
Water inlet 16.7 - 22.6 (1.7 - 2.3, 13 - 16) M
Thermostat housing 16.7 - 22.6 (1.7 - 2.3, 13 - 16)
Rear water outlet 16.7 - 22.6 (1.7 - 2.3, 13 - 16)
Water connector (Water control valve cover) 16.7 - 22.6 (1.7 - 2.3, 13 - 16)
Water suction pipe 16.7 - 22.6 (1.7 - 2.3, 13 - 16)

CO-31
SERVICE DATA AND SPECIFICATIONS (SDS)

CO-32